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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 415 records · Page 23

An Assessment of Evaluation Practices of Low- And Moderate-Income Solar Programs

As concerns about social equity and clean energy rise, state and local governments, utilities, and non-profit organizations are offering at least 41 active programs in 21 states to promote solar adoption as a way to reduce energy bills for low- and moderate-income (LMI) households while meeting other policy goals such as job creation and clean energy generation. A new study from Berkeley Lab looks at how those programs are being evaluated. The report provides background on how they seek to address LMI household energy burdens and gives a brief discussion of the art and science of program evaluation, drawn from decades of experience in energy efficiency programs. It then turns to how LMI solar programs are currently being evaluated, highlighting trends among evaluation methods, metrics tracked, and best practices employed. A few programs are explored in more depth to illustrate notable practices that could be applied to other program evaluations. These LMI solar programs are mostly young, operate on tight budgets, and vary considerably in their design and stated goals. Consequently, well-designed program evaluation is critical to better understand what works, what could be improved, and how to maximize program impacts under budget constraints.

14 SOLAR ENERGY↗

Crystalline Silicotitanate (CST) Ion Exchange Media Performance Evaluations to Support TSCR DSA IX Media Equilibrium Contacts

The primary objective of this work is to calculate the maximum loading expected on the Hanford Tank Side Cesium Removal (TSCR) ion exchange columns. A key consideration in the design of the columns is the amount of 137 Cs that loads onto the Crystalline Silicotitanate (CST) and the heat generated by the loaded column during storage. Per request of Washington River Protection Solutions (WRPS), Savannah River National Laboratory (SRNL) has utilized ZAM, a computer program developed by the research group of Professor Rayford G. Anthony of Texas A&M University, to predict the cesium loading on the CST for a variety of waste compositions expected to be processed by TSCR. The study evaluated cesium loadings for the following waste compositions: 1. Seventeen DFLAW campaign batches to cover projected supernate composition ranges within which TSCR may be expected to operate within the first ten years, 2. Hanford tank AP-105 and AP-107 waste solutions that will be processed by the TSCR system.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Relevant Additive Manufacturing Materials for Wind Industry

The purpose of this report is to equip wind industry professionals with the relevant material testing and properties of large format extrusion-based additive manufacturing processes. Discussion on the printability and processing of different classes of materials (i.e. low temperature, high temperature, thermoplastics, elastomeric, foam, etc.) is provided as well as relevant test standards and methods. Existing results for materials and properties are detailed. A companion document titled “Additive Manufacturing Design Guidelines for Wind Industry” covers the seven families of additive manufacturing, the relevance of each family to the wind industry, and design guidelines and considerations for the most relevant processes.

17 WIND ENERGY↗

Flow rate optimization for a small liquid argon system at Fermilab.

This analysis highlights the dominant role of pressure loss in filter disks, emphasizing its crucial consideration during the design phase to ensure optimal fluid flow. Additionally, the significance of vapor quality at the transfer line inlet is identified as a key factor impacting the fill rate. Reducing inlet vapor quality and exploring the use of subcooled liquid are recommended approaches to enhance system performance.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

Ply Strength Prediction of Unidirectional Continuous Carbon Fiber Composites

As inhomogeneous orthotropic materials, composite mechanical properties can be difficult to predict. Even with tight fabrication process controls, there is always some microstructural variation that will affect these properties. As a highly defect-dependent phenomena, mechanical strength is even more subject to variation, especially considering that composites exhibit multiple potential failure modes. The most direct way to determine composite material strength is via experimental testing, maintaining loading and specimen morphology as close as possible to the in situ states. When multiple materials and designs are being considered, this process is often prohibitively costly and slow. However, some approximations and rules of thumb can consistently guide the design process and consideration of alternatives.

36 MATERIALS SCIENCE↗

Lightweight Metal Stamping Optimization Enabled by Artificial Intelligence

Successfully manufacturing an automotive body structure made via the sheet metal stamping process depends upon simultaneous consideration of component design, tooling design, stamping process control, and material properties. In many cases, introducing lightweight sheet materials (e.g., aluminum alloys, magnesium alloys, advanced high strength steels) holds the potential to significantly reduce vehicle weight, but challenges the stamping process by introducing materials with inherently less ductility. Successful and repeatable applications require co-developing the stamping process controls with the varying material properties, including formability. During the stamping process, as soon as the forming limit of the sheet is exceeded, the material shows localized necking which quickly leads to splits. Controlling process variability to avoid these material splits will enable deployment of less formable, lighter, and stronger materials for stamped automotive components. A typical optimization procedure for manufacturing requires an iterative process involving parameter setting, execution of computational simulations, and modifying the parameters. The entire process demands substantial computational time, making it impractical for real-time feedback towards rapid corrective actions required for in-line control for running production processes. To overcome this challenge, artificial intelligence (AI) can be leveraged to determine optimal manufacturing parameters within a single manufacturing cycle time. This research proposes an in-line optimization framework incorporating a trained AI model to predict kidney-shaped die forming. Preliminary results indicate that the AI framework can accurately predict draw-in values based on a given parameter set, a process referred to as forward prediction. Furthermore, the AI framework can also predict the optimal parameter set that leads to the desired draw-in values, referred to as inverse optimization (or backward prediction). This research has been performed in collaborations with USCAR (US Council for Automotive Research) and AutoForm. The members of USCAR are Ford, GM, and Stellantis.

36 MATERIALS SCIENCE↗

ECFA Higgs, electroweak, and top Factory Study

The ECFA Higgs, electroweak, and top Factory Study ran between 2021 and 2025 as a broad effort across the experimental and theoretical particle physics communities, bringing together participants from many different proposed future collider projects. Activities across three main working groups advanced the joint development of tools and analysis techniques, fostered new considerations of detector design and optimisation, and led to a new set of studies resulting in improved projected sensitivities across a wide physics programme. This report demonstrates the significant expansion in the state-of-the-art understanding of the physics potential of future e+e- Higgs, electroweak, and top factories, and has been submitted as input to the 2025 European Strategy for Particle Physics Update.

Altmann, J. [Monash U.]↗

Advanced Intra-Cycle Detection of Pre-Ignition Events through Phase-Space Transforms of Cylinder Pressure Data

The widespread adoption of boosted, downsized SI engines has brought pre-ignition phenomena into greater focus, as the knock events resulting from pre-ignitions can cause significant hardware damage. Much attention has been given to understanding the causes of pre-ignition and identify lubricant or fuel properties and engine design and calibration considerations that impact its frequency. This helps to shift the pre-ignition limit to higher specific loads and allow further downsizing but does not fundamentally eliminate the problem. Real-time detection and mitigation of pre-ignition would thus be desirable to allow safe engine operation in pre-ignition-prone conditions. This study focuses on advancing the time of detection of pre-ignition in an engine cycle where it occurs. Furthermore, phase space transforms through time-delay embedding of cylinder pressure and principal component analysis were applied to same-cycle detection of pre-ignition and shown to enable detection on the order of a crank degree earlier than deviation in cylinder pressure can be identified through direct statistical observation of the pressure data. Additionally, it appears that the deviation of the trajectory in phase space may offer the opportunity to extend this method to further extend the detection window and allow more time for mitigation actions to occur.

42 ENGINEERING↗

Understanding Community Microgrids

Increasing need for distribution circuit reliability and resilience prompt a clearer understanding of community microgrid interconnection and operational requirements. While customer-owned, behind-the-meter microgrid implementation is not always simple, increasing demand for reliability has commercialized many installation approaches. This rapid commercialization has broadened industry understanding of single-customer microgrid integration. Moreover, off-grid behaviors of such microgrids are not required to meet utility standard interconnection requirements. However, multi-customer community microgrids (utility- or third-party operated), are less well explored and introduce more complex design and operational challenges. The control of DER along with distribution automation devices, unmanned operation, protection coordination, and other aspects makes community microgrids challenging to implement and operate in both on-grid and off-grid modes. This whitepaper is a technical primer for understanding community microgrids. It provides a foundation for understanding the components, configurations, design, and operational considerations for community microgrids.

14 SOLAR ENERGY↗

Titanium Wire Arc Additive Manufacturing Inert Enclosure and Material Handling Safety Considerations

Wire arc additive manufacturing (WAAM) via metal inert gas (MIG)/gas metal arc welding (GMAW) is a viable option for fabrication of large-scale titanium parts; however, it introduces new safety hazards associated with both the material and the additional system hardware required for the process. Localized gas shielding of the weld arc via standard GMAW torch is inadequate for titanium due to its affinity for oxygen; thereby requiring the use of an inert enclosure to protect the weld from entraining oxygen. The use of the inert enclosure presents potential safety hazards such as operator asphyxiation and brings up discussion of confined space considerations. In addition, the titanium welding process creates pyrophoric titanium soot residue around the deposit, which can undergo deflagration during part cleaning and part removal. This paper provides an overview of the titanium WAAM process along with safety considerations for the design and operation of the inert enclosure as well as functional solutions for the safe handling of the titanium soot by-product.

Walters, Alex↗

RESCue Model (RESCue Experiment and Model) [SWR-24-84]

The Renewable Energy and Storage Cybersecurity Research (RESCue) project is a collaborative effort aimed at securing the rapidly growing deployment of transmission-connected hybrid renewable energy systems, consisting of a combination of wind, solar, and/or energy storage equipment, against escalating cyber threats. This project brings together major original equipment manufacturers (OEMs) of wind, solar, and energy storage, along with major asset owners and DOE National Laboratories, to collectively identify cyber threats, assess risks, and develop robust cybersecurity strategies and solutions. The development of hybrid reference architectures has provided comprehensive blueprints for the secure design and integration of hybrid renewable energy systems, accounting for their unique characteristics and interdependencies. Additionally, NREL has created a cyber-resilient design framework that integrates cybersecurity considerations from the start of the system lifecycle, ensuring security is "baked in" from the initial design phase. The research thrusts for the project included (i) development of hybrid reference architectures and (ii) a cyber-resilient design framework for hybrid energy systems. The reference architectures has provided comprehensive blueprints for the secure design and integration of hybrid renewable energy systems, accounting for their unique characteristics and interdependencies. Additionally, NREL has created a cyber-resilient design framework that integrates cybersecurity considerations from the start of the system lifecycle, ensuring security is "baked in" from the initial design phase. A demonstration experiment was developed for one of the architectures using NREL's Cyber Range resources. This experiment configuration, deployable using open-source tools, is provided here in this repository. Additional models were developed for the wind and solar architectures as well, however the configurations for only the Energy Storage scenario are provided here: https://www.nrel.gov/docs/fy24osti/89921.pdf

Hasandka, Adarsh↗

Human-System Interface Design Review Guidelines

The U.S. Nuclear Regulatory Commission (NRC) staff reviews the human factors engineering (HFE) aspects of nuclear power plants in accordance with the Standard Review Plan (NUREG-0800, Standard Review Plan for the Review of Safety Analysis Reports for Nuclear Power Plants: LWR Edition). The Human Factors Engineering Program Review Model (NUREG-0711, Revision 3, issued November 2012) contains detailed design review procedures. As part of the review process, the interfaces between plant personnel and the plant's systems and components are evaluated for conformance with HFE guidelines. This document, Human-System Interface Design Review Guidelines (NUREG-0700, Revision 3), provides the guidelines necessary to perform this evaluation. The review guidelines address the physical and functional characteristics of human-system interfaces (HSIs). Because these guidelines only address the HFE aspects of design and not other related considerations, such as instrumentation and control and structural design, they are referred to as HFE guidelines. In addition to the review of actual HSIs, the NRC staff can use the NUREG-0700 guidelines to evaluate a design-specific HFE guidelines document or style guide. The HFE guidelines are organized into four basic parts, which are divided into sections. Part I contains guidelines for the basic HSI elements: information displays, user-interface interaction and management, and analog displays and controls. These elements are used as building blocks to develop HSI systems to serve specific functions. Part II contains the guidelines for reviewing the following HSI systems: alarm system, safety parameter display system, group-view display system, soft control system, computer-based procedure system, automation system, and communication system. Part III provides guidelines for the review of workstations and workplaces. Part IV provides guidelines for the review of HSI support (i.e., maintainability of digital systems and degraded HSI and instrumentation and control conditions).

42 ENGINEERING↗

Grid-Forming Storage Networks: Analytical Characterization of Damping and Design Insights

Grid-forming storage resources are critical to the operation of power grids with high renewable penetration. Over the years, there has been considerable emphasis on understanding the benefits these inverter-based storage resources bring towards managing volatility and enhancing grid reliability but little is studied about the supplementary advantages latent in their operation. This paper investigates one such application in which we explore the impact of grid-forming distributed storage in damping low-frequency inter-area oscillations. We present a detailed analysis characterizing the impact of inverter-droop and storage size on the slower eigenvalues, highlighting potential design considerations for enhancing system stability.

Chatterjee, Kaustav [BATTELLE (PACIFIC NW LAB)] (O↗

Wind turbine blade design with airfoil shape control using invertible neural networks

Wind turbine blade design is a highly multidisciplinary process that involves aerodynamics, structures, controls, manufacturing, costs, and other considerations. More efficient blade designs can be found by controlling the airfoil cross-sectional shapes simultaneously with the bulk blade twist and chord distributions. Prior work has focused on incorporating panel-based aerodynamic solvers with a blade design framework to allow for airfoil shape control within the design loop in a tractable manner. Including higher fidelity aerodynamic solvers, such as computational fluid dynamics, makes the design problem computationally intractable. In this work, we couple an invertible neural network trained on high-fidelity airfoil aerodynamic data to a turbine design framework to enable the design of airfoil cross sections within a larger blade design problem. We detail the methodology of this coupled framework and showcase its efficacy by aerostructurally redesigning the IEA 15-MW reference wind turbine blade. The coupled approach reduces the cost of energy by 0.9% compared to a more conventional design approach. This work enables the inclusion of high-fidelity aerodynamic data earlier in the design process, reducing cycle time and increasing certainty in the performance of the optimal design.

17 WIND ENERGY↗

Reference Station Design for Heavy-Duty Vehicles

Five alternative design configurations for a heavy-duty hydrogen refueling truck stop are detailed in this work. Each of the station concepts provides fast, 5-minute, 50 kg fills of up to 4 vehicles simultaneously, with a station capacity of 4200 kg/day. Two on-site production stations using PEM electrolysis are considered: one with off-peak production of the daily capacity; and one with on-demand production of hydrogen during vehicle refueling. Three delivered liquid hydrogen station concepts are considered: one with the same, high-pressure cascade storage system for dispensing as the electrolysis supplied stations, with low-pressure vaporization of the liquid hydrogen and pressurization via a compressor; and two with on-demand pressurization: one by low-pressure vaporization and compressors; and one with a cryogenic pump and high-pressure vaporization. Design, economic, and operational considerations for each of the components needed in these station concepts is provided. Of all the station concepts, the delivered liquid station with a low-pressure vaporizer and a cascade dispensing system has the lowest capital costs and equipment footprint, but the second highest operating costs primarily due to high costs for liquid hydrogen delivery. The lowest operating cost station is that with on-site production via PEM electrolysis at off-peak hours with a cascade delivery system. The low-pressure buffer storage system and electrolyzers have a large footprint and considerable capital costs, but could result in a low total cost of ownership, depending on the design timeline. The liquid hydrogen station with a cryo-pump has moderate capital costs, the lowest operating costs of the three delivered hydrogen stations, and the same small equipment footprint as the delivered liquid, cascade dispensing system. As cryogenic pumping technology improves and the capital costs for these pumps decreases, this station concept will become even more favorable. Three-dimensional renderings of the five station concepts provide station designers with a starting point for the development of heavy-duty refueling stations.

08 HYDROGEN↗

Separable shape tensors for aerodynamic design

Airfoil shape design is a classical problem in engineering and manufacturing. In this work, we combine principled physics-based considerations for the shape design problem with modern computational techniques using a data-driven approach. Modern and traditional analyses of two-dimensional (2D) and three-dimensional (3D) aerodynamic shapes reveal a flow-based sensitivity to specific deformations that can be represented generally by affine transformations (rotation, scaling, shearing, and translation). We present a novel representation of shapes that decouples affine-style deformations over a submanifold and a product submanifold principally of the Grassmannian. As an analytic generative model, the separable representation, informed by a database of physically relevant airfoils, offers: (i) a rich set of novel 2D airfoil deformations not previously captured in the data, (ii) an improved low-dimensional parameter domain for inferential statistics informing design/manufacturing, and (iii) consistent 3D blade representation and perturbation over a sequence of nominal 2D shapes.

42 ENGINEERING↗

Grassmannian Shape Representations for Aerodynamic Applications: Preprint

Airfoil shape design is a classical problem in engineering, science, and manufacturing. Our motivation is to combine principled physics-based considerations for the shape design problem with modern computational techniques informed by a data-driven approach. Traditional analyses of airfoil shapes emphasize a flow-based sensitivity to deformations which can be represented generally by affine transformations (rotation, scaling, shearing, shifting). We present a novel representation of shapes which decouples affine-style deformations from a rich set of data-driven deformations over a submanifold of the Grassmannian. The Grassmannian representation, informed by a database of physically relevant airfoils, offers (i) a rich set of novel 2D airfoil deformations not previously captured in the data, (ii) improved low-dimensional parameter domain for inferential statistics, and (iii) consistent 3D blade representation and perturbation over a sequence of nominal shapes.

blade representation↗

Grassmannian Shape Representations for Aerodynamic Applications

Airfoil shape design is a classical problem in engineering, science, and manufacturing. Our motivation is to combine principled physics-based considerations for the shape design problem with modern computational techniques informed by a data-driven approach. Traditional analyses of airfoil shapes emphasize a flow-based sensitivity to deformations which can be represented generally by affine transformations (rotation, scaling, shearing, shifting). We present a novel representation of shapes which decouples affine-style deformations from a rich set of data-driven deformations over a submanifold of the Grassmannian. The Grassmannian representation, informed by a database of physically relevant airfoils, offers (i) a rich set of novel 2D airfoil deformations not previously captured in the data, (ii) improved low-dimensional parameter domain for inferential statistics, and (iii) consistent 3D blade representation and perturbation over a sequence of nominal shapes.

blade representation↗